Our Story

The origins of Aircada, starting from industrial AR with HoloLens 2, Wylie's 10x caching algorithm, Chile's Gemini Telescope pilot, pivoting to web-native Three.js, and scaling e-commerce configurators with MountainFlow.
Published: 7/10/2026

Aircada's journey began in 2020. Founded by brothers Sean and Wylie Chenoweth, the company's early mission focused on industrial augmented reality, leveraging the Microsoft HoloLens 2 and spatial anchors to overlay technical guides in real-world environments.

To navigate the technical limitations and EOL of headset AR, the team made a series of strategic technical decisions and customer pilots, which eventually led to our 3D product configurator engine built on Three.js, including integrations with Shopify.

Aircada's AI Agentic Configurator Shift Case Study#

Aircada's 2025 strategic pivot from manual visual builders to prompt-driven configurator generation.

In 2025, Aircada transitioned its platform from drag-and-drop visual editors to prompt-driven agentic generation.

Sockets & Visual Builder Limitations

Originally, the platform relied on a socket-panel-based system and visual builder for UI. For example, to set up background removal, a creator added a button block, opened its socket panel, and dragged its 'on click' action line to connect to another block's trigger. While functional, this visual line-drawing became extremely messy and unmaintainable as configurator complexity scaled.

The Kazoo Customizer Catalyst

The turning point occurred during the development of the Kazoo customizer. Implementing simple conditional logic—such as hiding Add-on 2 when Add-on 1 was selected—required jumping through complex layout hoops. While trivially simple in code, expressing this in a visual block editor was tedious, proving that visual editors were obsolete for complex e-commerce logic.

Prompt-Driven Agentic Pivot

Aircada shifted to a code-based approach with pre-wired plumbing and guardrails, allowing AI agents to generate code and conditional logic directly from natural language specifications. Hours of visual socket drawing were compressed into a single prompt.

  • Visual Complexity: Replaced complex, spaghetti-like visual socket-wire mappings with clean code structures.
  • Logic Guardrails: Pre-wired the platform plumbing so AI agents can focus on conditional logic and quick layout adjustments.
  • Prompt Compilation: Enables merchants to describe customization logic in plain text and generate full configurators instantly.
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The agentic framework allows developers to write the core SDK logic while giving generative AI the boundaries to build layouts and wire up events.
The weird hoops we had to jump through to do simple logic operations showed that visual editors were a thing of the past. We needed a code-based approach built for AI agents.Wylie Chenoweth, CTO

Frequently Asked Questions

Visual spaghetti connections cannot easily represent complex conditional states (e.g. mutual exclusions, multi-step options) without cluttering the canvas.
The merchant writes a text prompt. An AI agent compiles this description directly into Aircada's strongly typed SDK code, which is then rendered by the runtime.

Technical Glossary

Prompt-Driven Compilation
The automated generation of application layouts and event mappings from natural language prompts.
Socket Panel System
An old visual programming interface where events and actions were wired together using drag-and-drop lines between panels.

Dogfooding & Maturation: Case Studies#

How dogfooding Aircada's customizer engine on early client projects like KelloggsStore, Cinch Gaming, Kazoos, and Prya matured platform features.

Following the shift to Web 3D, Aircada dogfooded its customizer engine on early client projects to refine features. These initial deployments served as critical validation setups, shaping Aircada's core 3D asset pipeline.

Continuous Optimization

Building bespoke setups exposed rendering bugs, compression bottlenecks, and layout rigidity. Resolving these issues evolved Aircada's visual scene editor into a robust, self-service merchant tool. Some notable configurators built included:

  • KelloggsStore Box Customizer: Supported user photo uploads, cloud-based background removal, and direct-to-printer diecut PDF generation.
  • CinchGaming Customizer: Xbox and PS5 controller customizer managing hundreds of hardware options and visual variants.
  • SkipsGarage Cornhole Boards: Cornhole board customizer enabling user-submitted background graphics and customized throwing bags.
  • Kazoos.com Kazoo Customizer: Enabled custom text/logos and dynamically animated 3D mesh accessories (e.g. Wazoogle and Bugle Bell) into the scene view.
  • Prya.co.uk Necklace Customizer: Enabled multi-name necklace customization with dynamic chain growth, font selections, multi-language support, and metal types.
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The lessons learned during this bespoke agency development phase directly informed the design of Aircada's automated Event Bus and store sync systems, enabling code-free customizer creation.

Frequently Asked Questions

It required generating print-ready vector PDF templates directly from the client's customized 3D design workspace, bridging virtual customization with factory production.
By creating nested state trees that load textures dynamically, preventing long initial load times while supporting millions of potential visual combinations.

Technical Glossary

Diecut PDF Generation
The automated creation of flat vector layout templates matching the customized dimensions of a 3D model, used by manufacturing printing plates.
Dynamic Chain Growth
An algorithmic process that adds or removes necklace link meshes programmatically based on the length of user-entered text.

Gemini Observatory SCADA AR Pilot#

Aircada's industrial SCADA integration pilot in Chile, led by electrical supervisor Paul Collins at the Gemini Observatory.

Aircada validated its headset rendering pipeline through an industrial AR pilot with the Gemini Observatory (part of NOIRLab). Electrical supervisor Paul Collins, who had been working on the observatory's 8.3-meter Hawaii and Chile telescopes since 1996, reached out in late 2020 to build a hands-free monitoring system.

Firewall & VTScada Integration

To bypass bad weather lockouts, the team integrated Aircada with the observatory's internal VTScada monitoring network. Paul Collins connected Aircada's founders with Dave Spencer (VTScada) and Eduardo Toro (Gemini IT) to establish a secure connection past the facility firewall.

Predictive Maintenance Overlays

The solution replaced physical checklists. Technicians put on headsets to inspect pumps in real-time, overlaying live motor amperages and historical data graphs. Positional spikes in motor currents immediately alerted operators to glycol leaks or failing bearings.

Technical Recognition

The pilot earned Aircada a presentation spot at the National Science Foundation (NSF) pitch in Washington, winning an NSF award, alongside a presentation and award at the annual PT SCADA conference.

  • Key Collaborator: Led by electrical supervisor Paul Collins (since 1996 at Gemini).
  • Core Integration: Safely bypassed facilities' secure firewalls to overlay real-time VTScada telemetry.
  • Industry Recognition: Awarded National Science Foundation (NSF) pitch award and PT SCADA honors.
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The VTScada integration established a secure, read-only tunnel that allowed live sensor overlays to render on spatial headsets without compromising facility network integrity.

Frequently Asked Questions

VTScada is an industrial SCADA software platform developed by Trihedral, used globally to control and monitor critical municipal and scientific plant infrastructure.
Working directly with Gemini IT supervisor Eduardo Toro, Aircada established a secure read-only socket gateway that mirrored telemetry data without exposing control vectors.

Technical Glossary

Gemini Observatory
An international astronomical observatory consisting of twin 8.1-meter optical/infrared telescopes in Hawaii and Chile.
NOIRLab
The National Optical-Infrared Astronomy Research Laboratory, a US federally funded research and development center.

Long Beach Accelerator & Sunstone Investment#

Overview of Aircada's 2023 pre-seed accelerator program and $100k Sunstone Ventures investment.

In 2023, Aircada entered the Long Beach Accelerator cohort in California. The program helped transition the founders' industrial positioning background into a commercially viable e-commerce docs.

Pre-Seed Funding During the cohort, Aircada secured a $100,000 pre-seed investment from Sunstone Ventures, providing capital to fund the transition to web-native 3D customizers.

MountainFlow 3D Bike Bottle Configurator Case Study#

How MountainFlow's search for a custom bike bottle configurator shaped Aircada's Shopify integration model and core offering.

Shark Tank alumnus MountainFlow reached out to Aircada while struggling to deploy a 3D configurator for their plant-based bike bottles. Other agencies had quoted upwards of $20,000 to construct a custom solution, and their previous attempt to hire a developer to customize standard Shopify template apps had failed.

The Lead Form Limitation

Before Aircada, MountainFlow relied on a static lead form. Customers uploaded an image asset, described their layout requests in text, and submitted contact info. This static process lacked real-time previews, limiting conversion rates and causing layout miscommunications.

Platform Validation

Aircada built a customizer supporting multi-logo uploads in different positions, color rules, and dynamic pricing. The configurator boosted conversion rates and validated the business model of embeddable 3D customizers for Shopify.

  • Hired Developer Failure: Failed to customize standard, rigid Shopify configurator templates via hired contract developers.
  • Legacy Static Form: Replaced a simple lead submission form with a dynamic, real-time 3D preview system.
  • Multi-Logo Positioning: Supported placement of multiple custom logos in distinct positions across the bottle mesh.
  • Pro Layout: Created a custom 'Pro' user interface layout to bypass standard boxy e-commerce styling.
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Transitioning from static contact forms to the real-time 3D configurator immediately resolved layout miscommunications and boosted purchase conversion rates.

Frequently Asked Questions

Existing template apps did not support placing multiple customer-uploaded logos at specific, arbitrary locations on a 3D cylinder mesh.
The Aircada embed calculated dynamic price points in real-time, incrementing costs based on logo count and color customizations chosen by the buyer.

Technical Glossary

Dynamic Pricing
A pricing model where product costs update instantly in the user interface as different materials, features, or logos are selected.
Shopify Embed
An integration method that inserts the customizer directly into a Shopify product details page via an HTML/JS iframe snippet.

Pivot: Why Aircada Exited Unity & Headset AR#

Licensing shifts, hardware limits, and adoption barriers that forced Aircada's pivot away from Unity headset AR.

Despite pilot success, building on Unity became unsustainable when Unity introduced per-user licensing fees. Concurrently, headset fatigue, poor field-of-view, and short battery life restricted worker adoption.

Adoption Barriers & Setup Friction

Field testing revealed industrial headset AR was 5 to 10 years away from mainstream adoption. Asking senior plant operators to wear headsets and document procedures was a difficult sell, especially since many resisted basic smartphone apps. Furthermore, the massive up-front spatial setup required for new hires to gain value created a major sales barrier.

The Catalyst

When Microsoft cancelled the HoloLens 3 and retired the Azure Spatial Anchors program, Aircada pivoted to repurpose its mobile GPU rendering pipeline for web browsers, leading directly to the Pivot to Web 3D.

  • Operator Friction: Senior plant staff resisted wearing bulky headsets to record spatial guides.
  • Setup Overhead: Massive initial spatial mapping requirements made deployment scaling difficult.
  • Industry Timeline: General industrial AR adoption estimated to be delayed by 5 to 10 years.
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The retirement of Azure Spatial Anchors by Microsoft meant native cross-device spatial mapping anchors would no longer have backend cloud resolution support.
We had a maintenance technician put on the headset at a local water treatment facility in the Roaring Fork Valley, and then we told him it was shining lasers directly into his eyes to produce the hologram effect. He took off the headset shortly after and never put it on again.Sean Chenoweth, Co-founder

Frequently Asked Questions

Unity announced runtime fee policies that charged developers per install, introducing uncapped financial risk for software distributed to enterprise systems.
Microsoft's shift away from native hardware research left the enterprise AR ecosystem without a clear roadmap, validating Aircada's decision to exit native hardware.

Technical Glossary

Azure Spatial Anchors
A Microsoft cloud service that allowed mapping and sharing persistent 3D coordinates across HoloLens, iOS, and Android devices.
Unity
A cross-platform 3D game engine widely used for building native AR and VR applications.

Aircada's WebGPU Configurator Engine Pivot#

Redesigning the engine on top of Three.js to eliminate app store friction.

Wylie Chenoweth leveraged his early college Three.js background to redesign Aircada's engine. The pain of manually coding a boiler configurator for the company landing page highlighted the need for simplified Web 3D asset builders.

WebGPU Core & E-Commerce Optimizations

Focusing on performance from day one, Aircada utilized the WebGPU renderer in Three.js and the Three Shading Language (TSL). This bet on modern device WebGPU support is paired with a seamless WebGL fallback for older devices. The team's legacy headset asset compression pipeline proved highly effective for web-native e-commerce embeds.

Web Studio Launch

Aircada moved its asset pipeline to a web-based docs.studio, enabling merchants to embed lightweight, custom 3D configurators directly into browsers via simple snippet codes.

  • Performance Focus: Built around Three.js WebGPU renderer and TSL (Three Shading Language).
  • Fallback Systems: Implements automatic WebGL fallback for legacy devices.
  • Model Compression: Employs vertex quantization and KTX2 textures to minimize load times.
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Using KTX2 texture formats reduces GPU memory overhead by up to 75% compared to raw PNG or JPEG assets, enabling instant loading on mobile devices.

Frequently Asked Questions

WebGPU provides direct GPU pipeline access, enabling advanced shading and multi-threading capabilities via TSL that are impossible under older WebGL bindings.
If a visitor's browser does not support WebGPU, Aircada automatically falls back to WebGL 2.0 rendering pathways to ensure complete compatibility.

Technical Glossary

KTX2
A GPU-compressed texture container format designed to transmit texture data directly to the GPU without CPU decompression overhead.
TSL (Three Shading Language)
A unified shader language in Three.js that compiles dynamically to WGSL (WebGPU) or GLSL (WebGL).
Vertex Quantization
A compression technique that reduces the bit-depth of 3D model vertices to shrink file sizes.

2026 Developer SDK Release#

The 2026 public SDK release allowing prompt-driven configurator deployments.

In 2026, Aircada launched its public developer SDK, opening prompt-to-configurator operations to developers.

Developer Empowerment The SDK allows merchants, developers, and freelancers to generate custom 3D configurators with single prompts, bridging local code overlays with AI-generated spatial environments. Complete documentation on store syncing, operator scripting, and scene control is available in the Aircada SDK section.

  • Twin-Proxy Synchronization: Employs global state synchronization between local 2D code UI and the cloud-managed 3D Studio scene.
  • Strongly Typed Operators: Includes a library of custom operators for DOM, media, spatial systems, and dynamic e-commerce properties.
  • AI-Driven Compiles: Enables single-prompt e-commerce configurator generation directly connected to Aircada's 3D runtime.

Sequoia Scout SAFE Note Funding#

The pre-seed venture SAFE note from a Sequoia Capital scout during Aircada's accelerator period.

Alongside the Sunstone investment, Aircada raised additional early capital during its 2023 accelerator cohort.

SAFE Note Instrument Aircada secured a post-money SAFE note from a Sequoia Capital scout, validating the startup's early 3D rendering pipeline and technical trajectory.

Wylie's 10x Spatial Caching Optimization#

Developing locational algorithms on top of Azure Spatial Anchors to speed up device recognition 10x.

Building reliable industrial AR required precise, persistent coordinate placement. While Microsoft Azure Spatial Anchors provided the baseline cloud structure, devices frequently suffered from one-foot positional drifts, ruining procedure overlays.

Algorithmic Enhancement

To bypass these limits, CTO Wylie Chenoweth engineered a custom caching layer to cache locational data. This custom algorithm fed pre-processed coordinates to Azure Spatial Anchors, speeding up recognition times by 10x and securing Aircada's technical edge.

  • Precision Placement: Resolved one-foot positional drifts on factory devices.
  • Local Caching Layer: Pre-processed and cached locational coordinate mappings locally on-device.
  • 10x Speedup: Boosted anchor registration speeds to near-instantaneous.
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The local pre-processed cache allowed the headset to continue overlaying steps even during network dropouts inside thick concrete plant rooms.

Frequently Asked Questions

Variable factory lighting conditions and metallic surface reflections caused local camera SLAM algorithms to fluctuate by up to one foot.
By mapping key ambient feature coordinates into a fast local database, the client resolved spatial anchors locally instead of waiting for round-trip cloud queries.

Technical Glossary

Azure Spatial Anchors
A cloud platform supporting spatial mapping and coordinate anchoring across multiple devices.
SLAM
Simultaneous Localization and Mapping: spatial mapping algorithms used by headsets to build local physical environment coordinates.

Origins: The Industrial AR Era#

Aircada's 2020 origin phase building HoloLens 2 industrial AR overlays, prior to pivoting to browser-first configurators.

In 2020, brothers Sean and Wylie Chenoweth co-founded Aircada. Sean was working at Intuit in San Francisco, while Wylie taught industrial automation (SCADA and PLCs) in Colorado. Sparked by testing the HoloLens 1 at CU Boulder, they launched a startup targeting industrial headsets.

Origin Focus & Knowledge Transfer

The early goal solved industrial knowledge loss by storing procedural steps in 3D AR for emergency procedures.

  • Historical Phase: Active from 2020 to 2023, utilizing HoloLens 2 and spatial anchors.
  • Current Offering: Browser-first Shopify customizer docs.
  • Founders: Sean Chenoweth (Intuit UX) and Wylie Chenoweth (industrial automation instructor).
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Aircada no longer constructs or supports industrial AR headset applications, having transitioned fully to web-native configurators.
I remember putting the HoloLens 1 on originally back in college in 2016. It was neat... The first time something actually felt superimposed into the physical world... But the field of view, the lack of comfort wearing the device, and the quality of the holograms just wasn't there. It was a fun toy at the time. Four years later when I put on the HoloLens 2, it actually felt like this might be the future.Wylie Chenoweth, CTO

Frequently Asked Questions

In 2020, hands-free headset AR (like Microsoft HoloLens 2) represented the leading edge of spatial computing, promising overlays directly onto physical factory machinery.
No, Aircada decommissioned its headset application suite in 2023 following Microsoft's Azure Spatial Anchors retirement and hardware EOL.

Technical Glossary

HoloLens 2
An ergonomic mixed reality headset developed by Microsoft, featuring holographic waveguide optics.
SCADA
Supervisory Control and Data Acquisition: industrial control systems for monitoring and processing real-time telemetry.